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Pfaff 591 Series: Maintenance Guide
Quick answer: Regular maintenance of your Pfaff 591 series machine is crucial for consistent stitch quality and preventing costly breakdowns. Focus on daily cleaning and lubrication, weekly inspection of wear parts like the rotary hook and take-up lever, and timely replacement of worn components.
Maintaining your Pfaff 591 industrial sewing machine is key to its longevity and consistent performance. This guide provides a practical maintenance schedule and identifies common wear parts, helping you keep your machine running smoothly and minimize downtime. Regular cleaning, lubrication, and timely replacement of worn components are essential for optimal operation.
Two-minute checks before you open anything
- Check needle for sharpness and straightness.
- Verify proper threading path and tension settings.
- Inspect the bobbin case and rotary hook area for lint buildup.
- Listen for any unusual noises during operation.
1. Rotary Hook high likelihood
How to tell
Skipped stitches, inconsistent stitch quality, frequent thread breakage, unusual noise from the hook area, or visible burrs/nicks on the hook point or race.
Fix
- Turn off and unplug the machine for safety.
- Remove the needle plate and bobbin case.
- Carefully inspect the rotary hook for any signs of wear, burrs, or damage on the hook point and the bobbin case race.
- If worn, loosen the set screws holding the hook in place and carefully remove it.
- Install a new rotary hook, ensuring it is correctly timed with the needle. Refer to your machine's service manual for precise timing instructions.
- Replace the bobbin case and needle plate.
- Test stitch on scrap material to confirm proper operation and stitch quality.
We stock various rotary hooks compatible with the Pfaff 591 series, including Fu chao SKRT592-R KRT-592, Desheng DSH-PF591 91-263490-91, KOBAN SKRT592V2R SKRT592V2-R 91-263495-91, and LEAGUE Koban SKRT592V2-S Original Rotary Hook 91-263340-91.
Parts involved: Rotary hooks & bobbin cases →
2. Take-Up Lever medium likelihood
How to tell
Thread fraying or breaking specifically at the take-up lever eyelet, inconsistent upper thread tension, or visible grooves/sharp edges on the thread guide portion of the lever.
Fix
- Turn off and unplug the machine.
- Inspect the take-up lever, paying close attention to the thread guide eyelet for any burrs, nicks, or wear that could abrade the thread.
- If damage is present, the take-up lever will need to be replaced. Consult your machine's manual for specific removal and installation instructions, as this can involve disassembling parts of the machine head.
- Install the new take-up lever, ensuring all connections are secure and the lever moves freely.
- Thread the machine and test stitch to verify proper tension and smooth thread flow.
We offer the Unbranded 91-011755-05 Take-Up Lever, compatible with Pfaff 591 and other models.
Parts involved: Head & mechanical parts → Thread path & tension →
Parts you may need for Pfaff
In stock, tested before dispatch, Buyer Protection on every order. Part types for this problem: Rotary hooks & bobbin cases, Head & mechanical parts, Thread path & tension, Screws, springs & small parts.
Flying Tiger HAX1 15x1 Sewing Machine Needles 100-Pack for Brother ...$ 13.99View part →
PFAFF 335H, 335, 335G Needle Plate, Feed Dog, Needle, Presser Foot,...$ 27.09View part →
Groz-Beckert B27 DCX27 81X1 FFG/SES Industrial Sewing Needles Nm 75...$ 37.49View part →
Groz-Beckert 134 DPX5 135X5 Industrial Sewing Needles 100-Pack for ...$ 39.29View part →
KRT470-R Rotary Hook for PFAFF 471-493, GOLDEN WHEEL 9910, 9920, 88...$ 33.99View part →
PFAFF 91-026746-04C Needle Plate & 91-026745-04C Feed Dog Set for 1...$ 36.09View part →All Pfaff parts → Rotary Hooks & Bobbin Cases → Head & Mechanical Parts → Thread Path & Tension →
3. Tension Support Rods low likelihood
How to tell
Upper thread tension issues that cannot be resolved by adjusting the tension discs, thread slipping out of tension, or visible bending/damage to the rods themselves.
Fix
- Turn off and unplug the machine.
- Examine the tension support rods for any signs of bending, corrosion, or damage that might prevent the tension discs from functioning correctly.
- If damaged, carefully remove the old tension support rods. This usually involves unscrewing them from the machine head.
- Install new tension support rods, ensuring they are securely fastened and provide proper support for the tension assembly.
- Re-thread the machine and test the upper thread tension, adjusting as necessary.
We provide Pfaff 91-013139-05 Tension Support Rods (2-Pack) suitable for the Pfaff 591.
Parts involved: Thread path & tension → Screws, springs & small parts →
4. Edge Guide low likelihood
How to tell
Inaccurate or inconsistent seam allowances, difficulty in guiding material straight, or visible bending, chipping, or wear on the guide's edge.
Fix
- Turn off and unplug the machine.
- Inspect the edge guide for any physical damage, such as bending, nicks, or excessive wear on the guiding surface.
- If damaged, loosen the mounting screws that secure the edge guide to the machine.
- Remove the old edge guide and install a new one, ensuring it is positioned correctly for your desired seam allowance.
- Tighten the mounting screws securely.
- Test with scrap material to confirm accurate guiding.
We offer an Edge Guide with Mounting Screws specifically for Pfaff 591 & Post-Bed Sewing Machines.
Parts involved: Presser feet & sewing parts → Screws, springs & small parts →
Maintenance schedule
| When | What to do | Why |
|---|---|---|
| Daily (or every 8-10 hours of operation) | Clean the bobbin case and rotary hook area. | Removes lint and thread scraps that can cause skipped stitches, thread breakage, and damage to the hook. |
| Daily (or every 8-10 hours of operation) | Oil all designated lubrication points. | Ensures smooth operation of moving parts, reduces friction and wear, and prevents overheating. |
| Daily (or every 8-10 hours of operation) | Check and replace the needle. | A sharp, straight needle prevents skipped stitches, fabric damage, and thread breakage. |
| Weekly | Clean the entire thread path. | Removes lint and debris from tension discs, thread guides, and take-up lever, ensuring consistent thread tension. |
| Weekly | Inspect the rotary hook for burrs or nicks. | Early detection of wear prevents damage to thread and fabric, and maintains stitch quality. |
| Monthly | Clean under the needle plate and feed dogs. | Removes accumulated lint and debris that can affect fabric feeding and stitch formation. |
| Monthly | Inspect the take-up lever and tension support rods. | Checks for wear, burrs, or damage that could affect thread flow and tension. |
| Every 3-6 Months (or every 500-1000 hours) | Perform a thorough cleaning and lubrication of all internal mechanisms. | Ensures all moving parts are free of debris and properly lubricated, extending machine life. |
| Annually (or every 2000 hours) | Professional service and timing check. | A technician can identify and address wear on critical components, adjust timing, and perform comprehensive preventative maintenance. |
Stop and call a technician if
- If you encounter persistent timing issues after replacing parts.
- If the machine makes unusual grinding or clunking noises that you cannot identify or resolve.
- If the motor is overheating or showing signs of electrical problems.
- For any complex repairs involving internal mechanisms or electronic components.
- If you are uncomfortable performing a specific repair or adjustment.
Prevent it coming back
- Always use the correct needle type and size for your fabric and thread.
- Change needles frequently, especially when working with dense materials or after extended use.
- Use high-quality thread to minimize lint buildup and thread breakage.
- Avoid forcing thick materials through the machine; ensure proper needle and presser foot pressure.
- Keep the work area clean to prevent dust and debris from entering the machine.
- Never operate the machine without proper lubrication.
Frequently asked questions
How often should I oil my Pfaff 591?
The Pfaff 591 series typically requires daily oiling at designated points, especially if used continuously. Always refer to your machine's specific manual for the exact oiling schedule and recommended oil type. Over-oiling can be as detrimental as under-oiling.
What kind of oil should I use for my Pfaff 591?
Use only high-quality, non-detergent, clear sewing machine oil specifically designed for industrial sewing machines. Never use household oils or automotive lubricants, as these can gum up the machine and cause damage.
Why is my Pfaff 591 skipping stitches?
Skipped stitches on a Pfaff 591 can be caused by several factors, including a dull or bent needle, incorrect needle size or type, improper threading, incorrect needle-to-hook timing, or a worn or damaged rotary hook. Check these components in order, starting with the needle.
Can I replace the rotary hook myself?
Replacing the rotary hook is a common maintenance task for experienced operators or technicians. It requires careful attention to detail, especially regarding timing the hook with the needle. If you are unsure, it's best to consult a qualified technician or refer to your machine's service manual for detailed instructions.
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